Hybrid composite hydroponic substrate system

ABSTRACT

A porous glass plant growth support structure, including a porous glass substrate and a plurality of interconnected pores distributed throughout the substrate. The substrate is typically formed from foamed glass and/or fused glass spheres and is characterized by a porosity of at least about 80 percent. The pore size is substantially between about 0.2 and about 5 millimeters and the substrate is sufficiently chemically stable such that water filling the plurality of interconnected pores experiences a pH shift of less than 0.5.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a utility application claiming priority to,and based upon, co-pending U.S. patent application Ser. No. 11/276,027,filed Feb. 10, 2006.

TECHNICAL FIELD

The novel technology relates generally to the field of ceramic materialsand, specifically, to a substrate system having a solid layer of porousfoamed vitreous material overlaying a loosely packed aggregate layer ofporous foamed vitreous material for water storage and root propagation.

BACKGROUND

Hydroponics is the science of growing plants in a nutrient solution withthe mechanical support of an inert medium. Hydroponics is an old art,and a variety of inert media are known as suitable for the germination,rooting and growth of plants. Such substrates include peat, vermiculite,perlite, fly ash, pumice, rock wool, glass wool, organic and inorganicfibers, polymers such as polyurethane, polystyrene, polyethylene, andthe like. These substrates have been used for true hydroponics or inquasi-hydroponic environments such as in admixtures with soil.Typically, the inert medium is either in the form of a contained looseparticulate, such as sand, or as a rigid and self-supporting structurethat can support growth of the plant. The rigid structure has somenotable advantages over the loose particulates, in particular theability to stand alone without a requisite container. However, the looseparticulate media tend to offer better pathways for water and gasses tobe delivered to and from the root systems.

One problem common to hydroponic gardening is overwatering. Hydroponictechniques lend themselves to the provision of excessive water to theplant root system, which may result in chlorosis, retarded growth,pallor, and, eventually death. In such situations, the water around theroots becomes stagnant and gasses dissolved therein are only urged toand from the roots through diffusion. Moreover, vital gasses quicklybecome depleted and waste gasses saturated in the water proximate theroots, exacerbating the situation. Thus, it is desired to reduce thestagnant water around the roots by circulating the water.

Most of the substrates currently known are solids with limited porosity.Some known substrates have attempted to add or increase the porosity ofthe substrate in order to better provide for gas exchange to the roots.One such substrate has been produced in the form of a sponge-like orforaminous foamed polymer body with conduits 1-5 millimeter in nominaldiameter, spaced about 1-8 mm apart and extending throughout thesubstrate. The conduits drain water from the substrate and providereservoirs of oxygen for the plant roots and at the same time allowsubstrate to hold some water that may then be available to the roots.The porosity of this substrate ranges from between 6 and 53 percent.Soil or the like is deposited on top of the substrate and a seed,cutting or small plant is placed in the soil. With the substrate underthe soil layer, over-watering induced problems are prevented, as excesswater drains from the substrate, filling the conduits with air andoxygen will be readily available to the roots.

Similarly to hydroponic agriculture, soil amendment is a common practicefor growing plants in places where adequate amounts of fertile soil areunavailable. In soil amendment, media similar to those discussed aboveare added to soils (especially in greenhouse applications) to improvewater retention and aeration around the root bed. Water is used as ameans to deliver nutrition and oxygen—soil amendments that increase theeffective soil porosity and water retention potential are vital forplant life and growth rate.

While useful in hydroponic and soil amendment applications, the abovesubstrates are still hampered by a lower than optimal porosity and lowcapacity for water infiltration and retention. Thus, there remains aneed for a highly porous substrate for supporting plant growth. Therealso remains a need for improves the aeration of soil and allows forbetter water filtration and irrigation. The present novel technologyaddresses these needs.

SUMMARY OF THE NOVEL TECHNOLOGY

The present novel technology relates to a layered foamed glass materialsystem for supporting plant growth, and the method for making the same.One object of the present novel technology is to provide an improvedfoamed glass plant support substrate material. Related objects andadvantages of the present novel technology will be apparent from thefollowing description.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a schematic view of a process for mixing a batch ofprecursors for a foamed glass article according to a first embodiment ofthe present novel technology.

FIG. 1B is a schematic view of a process for firing a foamed glassarticle mixed according to FIG. 1A.

FIG. 2 is a partial perspective view of roots infiltrating the porosityof the foamed glass article of FIG. 1B.

FIG. 3 is a cutaway elevation view of the article of FIG. 2 as partiallyimmersed in water and supporting plant growth.

FIG. 4 is a plan view of a plurality of crushed foamed glass pebblesaccording to a second embodiment of the present novel technology.

FIG. 5 is a cutaway elevation view of the article of a hydroponic systemincluding foamed glass media as shown in FIG. 4 mixed with soil andsupporting root growth.

FIG. 6 is a cutaway elevation view of the article of a hydroponic systemincluding foamed glass media as shown in FIG. 4 and supporting rootgrowth.

FIG. 7 is a cutaway elevation view of the article of a hydroponic systemincluding a foamed glass substrate member over a layer of foamed glassmedia as shown in FIG. 4 and supporting root growth.

FIG. 8 is an enlarged view of FIG. 7.

FIG. 9 is a cutaway elevation view of a hydrop[onic system like that ofFIG. 7, except the porous media are formed of agglomerated glass, metaland/or polymer spheres.

FIG. 10 is a cutaway view of a porous substrate or pellet formed of afoamed glass/sphere composite.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

For the purposes of promoting an understanding of the principles of thenovel technology and presenting its currently understood best mode ofoperation, reference will now be made to the embodiments illustrated inthe drawings and specific language will be used to describe the same. Itwill nevertheless be understood that no limitation of the scope of thenovel technology is thereby intended, with such alterations and furthermodifications in the illustrated device and such further applications ofthe principles of the novel technology as illustrated therein beingcontemplated as would normally occur to one skilled in the art to whichthe novel technology relates.

FIGS. 1A-4 illustrate a first embodiment of the present noveltechnology, a lightweight foamed glass substrate 10 characterized byvoluminous, interconnecting pores 15 for supporting plant growth. Asillustrated schematically in FIGS. 1A-B, a powdered glass precursor 20,such as recycled waste glass, is mixed with a foaming agent 22(typically a finely ground non-sulfur based foaming agent, such ascalcium carbonate). The foaming agent is typically sized in the averagerange of about 80 to minus 325 mesh (i.e. any particles smaller thanthis will pass through—typically, the apertures in 80 mesh are betweenabout 150 and about 200 micrometers across and the apertures in −352mesh are between about 40 and about 60 micrometers across). Moretypically, the foaming agent has a particle size between about 5 andabout 150 microns. Additional plant growth nutrient material 24 is alsotypically added to the starting mixture to vary or enhance the plantgrowth characteristic of the final product 10. Further, foamed glass,like most ceramics, is naturally hydrophobic. As hydrophobic surfacesare not conducive to wetting and impede capillary action, an agent istypically added to amend the surface properties to make the foamed glassmore hydrophilic. Such an agent may be a large divalent cationcontributor, such as ZnO, BaO, SrO or the like. The hydrophilic agent istypically added in small amounts, typically less than 1.5 weight percentand more typically in amounts of about 0.1 weight percent.

The combination is mixed 26, and the resulting dry mixture is thenplaced into a mold 28. Typically, the mixture is placed into the mold 28in the form of several rows of the mixture, such as in mounds or pilesof mixture typically having a natural angle of repose of about 15 to 50degrees, although even greater angles to the horizontal can be achievedby compressing the dry mixture. The mold 28 is typically a refractorymaterial, such as a steel or ceramic, and is more typically made in theshape of a frustum so as to facilitate easy release of the final foamedglass substrate 10. Typically, the inside surfaces of the mold 28 arecoated with a soft refractory release agent to further facilitateseparation of the foam glass substrate from the mold 28.

The so-loaded mold 28 is placed into a furnace for either a batch orcontinuous foaming process, and the mixture is then heated 30 in orderto sinter, fuse, soften and foam the mixture and thereby produce afoamed glass substrate 10 having a desired density, pore size andhardness. As the powdered mixture is heated to above the softening pointof glass (approximately 1050 degrees Fahrenheit) the mixture begins tosoften, sinter, and shrink. The division of the powdered mixture intorows or mounds allows the glass to absorb heat more rapidly and totherefore foam faster by reducing the ability of the foaming glass toinsulate itself. At approximately 1058 degrees Fahrenheit, the calciumcarbonate, if calcium carbonate has been used as the foaming agent,begins to react with some of the silicon dioxide in the glass to producecalcium silicate and carbon dioxide. Carbon dioxide is also formed byany remaining calcium carbonate once the mixture reaches 1274 degreesFahrenheit, above which calcium carbonate breaks down into calcium oxideand carbon dioxide gas. The release of carbon dioxide and its expansionand escape through the softened, viscous glass is primarily responsiblefor the formation of cells and pores in the softened glass mass. Themixture in the mold 28 is held for a period of time at a peak foamingtemperature of, for example, between about 1275 and about 1700 degreesFahrenheit, or even higher, depending on the properties that aredesired. By adjusting the firing temperatures and times, the density andhardness as well as other properties of the resultant substrate 10 maybe closely controlled.

As the furnace reaches foaming temperatures, each mass of foaming glass,originating from one of the discrete rows or mounds, foams until itcomes into contact and fuses with its neighbors. The fused mass offoaming glass then expands to conform to the shape of the walls of themold, filling all of the corners. The shapes and sizes of the initialmounds of mixture are determined with the anticipation that the foamingmixture exactly fill the mold. After the glass is foamed to the desireddensity and pore structure, the temperature of the furnace is rapidlyreduced to halt foaming of the glass. When the exterior of the foamedglass in the mold has rigidified sufficiently, the resultant body 10 offoamed glass is removed from the mold 28 and is typically then placedinto a lehr for annealing. The temperature of the lehr is typicallyslowly lowered from the softening temperature of the glass to ambienttemperature to anneal the porous block of foamed glass 10. Once cooled,any skin or crust is typically cut off of the foamed glass substrate 10,which may then be cut or otherwise formed into a variety of desiredshapes. Pore size can be carefully controlled within the range of about5 mm to about 0.5 mm, and is typically controlled such that theinterconnected or open porosity may readily accommodate a typical plantroot 35 (see FIG. 2). Substrate density can be controlled from about 0.4g/cc to about 0.15 g/cc. Typically, the bulk density of the crushed foammay be as low as 50% of the polyhedral density.

The substrate 10 is typically either formed as either crushed pebbles 50(typically sized to be less than 1 inch in diameter) or machinedpolyhedral shape (see FIG. 4). The crushed substrate material 50 may beused to retain water and increase air volume in given soil combinations.The polyhedrally shaped substrate bodies 10 are typically sized andshaped as growing media for seeds and immature plants, such as for usein soil or hydroponic systems 40 (see FIGS. 3 and 5). The foamed glasssubstrate material 10 is thus used to improve aeration and waterretention in agricultural systems, and the porous polyhedral material 10also provides a sufficiently spacious path for root growth andattenuation. The foamed material 10 is typically resistant to aqueouscorrosion and has minimal impact on solution pH. Typically, the foamedmaterial 10 is doped (in batch stage, prior to foaming) with specificnutritional species 24 (such as, but not limited to including P, Mg, Ca,K, and transition metals) as may be desired by the grower. The foamedglass substrate 10 can typically hold between about 1.5 and about 5times its own weight in water in the plurality of interconnected pores.The foamed glass substrate 10 is typically chemically stable as formed,but may be given a pretreatment wash to further increase its chemicalstability.

Crushed foam bodies 50 may be rapidly made by an alternate method. Usingsoda-lime glass frit or powder as the glass component 22, the processingis similar to that described above but without the annealing step. Thealternate method employs the same foaming temperature ranges as relatedabove. The batch material consists of up to 8 percent by mass limestone,magnesite, or other applicable foaming agent 22, usually less than 2percent by mass nutrients 24 (added as oxides, carbonates, nitrates, orother suitable forms), with the balance being a borosilicate, silicate,borate or phosphate glass frit 22. The batch is then placed in atypically shallow mold 28, more typically having a configuration of lessthan 2″ batch for every square yard of mold surface. The mold 28 istypically then heated to approximately 250° C. above the dilatometricsoftening point for soda-lime glass (or the equivalent viscosity forother glass compositions) and allowed to foam. The mold 28 is held atthe foaming temperature for less than 30 minutes and then pan quenched,i.e. substantially no annealing is allowed to occur This method yields amaterial 10 of density typically less than 0.15 g/cc, and more typicallyas low as about 0.03 g/cc. This material 10 is then crushed intopebbles, with a corresponding lower bulk density as per theabove-described method. Material made by this alternate method hassimilar chemical properties as described above, can accommodate an evenlarger nutrient content, but has substantially lower strength.

Still another alternate method of preparing foamed glass substratematerial 10 is as follows. A batch is prepared as discussed above andpressed into small (typically less than 5 mm diameter) pellets. Thepellets are rapidly heated, such as by passage through a flame source,passage through a rotary furnace, or the like. Typically, the pelletsare heated to about 1500 degrees Fahrenheit, such as to cause the pelletto expand as a foam particulate without the need for a mold. Thismaterial yields the weakest, but least dense foam particles. The typicaldensity may be as low as 0.02 g/cc or as high as 0.2 g/cc.

The foamed glass substrate 10, either in polyhedral body form or crushedproduct form, may serve as a root system support and an aeration and/orwater retention aid. The material 10 typically enjoys a void fraction ofat least about 80 percent. The substrate 10 is typically mechanicallymixed with as little as 15% by volume soil or soil mixture and this newmixture will still generate solution chemistry dominated by soil.

The polyhedral product 10 typically functions as a supporting substratefor both soil based and hydroponic applications. The polyhedralsubstrate 10 may be tailored to be compatible with mildly acidic,neutral, or mildly alkaline solution pH. The pore network 15 iscompatible with root propagation through the material 10. The porenetwork typically has surface adhesion or adsorption properties suchthat chemical additives 51, such as plant growth nutrients, herbicides,pesticides or combinations thereof, may be physically adsorbed thereontofor later release. Typically, these additives are added in smallamounts, such as a few weight percent (0.5 1, 2, 5, or the like) of thesubstrate product 10.

EXAMPLE 1

A plant growth support substrate 10 having a pore network 15 and plantnutrients embedded therein is produced from a precursor batch of about 3weight percent calcium carbonate sized at minus 200 mesh, about 2 weightpercent high-potassium nutrient, about 0.1 weight percent ZnOhydrophilic agent, and about 95 weight percent recycled plate glassground to minus 140 mesh, 60 to 100 mesh, are mixed together. Theresulting mixture is placed into a stainless steel mold having insidedimensions of 4.25 inches by 4 inches by 8.25 inches. The mold iscovered with a ½ inch stainless steel plate. The mold with the mixturetherein is then fired to 1250 degrees Fahrenheit for 60 minutes. Thetemperature is next ramped to 1450 degrees Fahrenheit for 30 minutes,where foaming takes place. The foamed glass in the mold is annealed bycooling slowly to room temperature over 120 minutes. The cooled block offoamed glass is removed from the mold, and the outer layer of crust isremoved (such as with a band saw) to expose the open porosity. Theresulting block typically has a density of about 14 pounds per cubicfoot and a pore size distribution ranging from about 0.5 to 2 mm. Theresulting block has final dimensions of 4 inches by 3.75 inches by 8inches. The resulting block has open, interconnected cells.

EXAMPLE 2

Plant growth media is formed by preparing a mixture of about 3 weightpercent calcium carbonate foaming agent sized at minus 200 mesh, about 3weight percent high phosphorous nutrient powder, about 0.1 weightpercent BaO hydrophilic agent, with the balance being recycled containerglass sized at minus 325 mesh. The mixture is then was positioned in amold and heated to a foaming temperature of 1400 degrees Fahrenheit for45 minutes followed by a rapid quench to room temperature. The resultingfoamed glass article is then crushed to produce foamed glass media withan open porosity of between about 80 and 90 percent with pores rangingfrom between about 1 and about 3 mm in diameter.

EXAMPLE 3

To prepare a block for cleaning tile, porcelain or enameled surfaces, aprocedure similar to that of Example 1 was used by mixing together about1.5 weight percent magnesite foaming agent (minus 200 mesh), about 3weight percent oxide nutrient, about 0.1 weight percent SrO hydrophilicagent, with the balance being recycled container glass (minus 325 mesh).The mixture is placed in a mold and heated to a foaming temperature ofabout 1360 degrees Fahrenheit for 60 minutes. The resultant foamed glassbody is then allowed to anneal and then cool, to yield a foamed glassarticle with a porosity of about 85 percent and a pore size distributionranging from about 0.05 to 0.2 mm. The article may be machined to shapeor crushed to form pebbles.

EXAMPLE 4

A foamed glass article may be prepared by mixing together about 0.1weight percent calcium carbonate foaming agent, about 0.1 weight percentZnO hydrophilic agent, about 2 weight percent oxide nutrient, and thebalance recycled container glass, with all powders being sized at minus325 mesh. The mixture is placed in a mold and heated to a foamingtemperature of about 1425 degrees Fahrenheit for about 25 minutes. Theresulting foamed glass article is typically annealed. The resultingarticle will have a porosity of about 90 to about 95 percent, with apore size distribution ranging from about 0.01 to 0.1 mm. The resultingblock can be machined into a desired shape, cut into smaller blocks, orcrushed into pebbles.

EXAMPLE 5

Crushed glass pebbles are prepared by mixing together about 2.5 weightpercent calcium carbonate foaming agent sized at minus 200 mesh, about 3weigh percent phosphorous and potassium oxides, about 0.1 weight percentZnO, about 20 weight percent sand sized at between 60 and 100 mesh, withthe remainder being powdered soda-lime-silica glass. The mixture isloaded into a mold and fired to about 1500 degrees Fahrenheit forfoaming for about 20 minutes, followed by a rapid quench. The resultingarticle has a porosity of between about 70 and about 80 percent with apore size distribution ranging from about 1 to 3 mm. The resultingarticle is crushed to produce pebbles between about 1 and about 2centimeters in diameter.

EXAMPLE 6

A porous crushed glass substrate is produced by mixing together betweenabout 5 and about 10% weight percent calcium carbonate sized at minus200 mesh, about 0.1 weight percent ZnO, about 3 weight percent K₂O, withthe balance being crushed recycled container glass ground to minus 325mesh. The mixture is loaded into a mold and heated to a 1600 degreeFahrenheit foaming temperature for 15 minutes. The resultant foamedglass article is annealed and cooled and has a porosity of between about90 and about 95 percent and a pore size distribution ranging from about2 to 4 mm. The resulting article may be cut or machined into a desiredshape or may be crushed into pebbles. Alternately, the annealing stepmay be replaced by a rapid quench and the block crushed into pebbles.

EXAMPLE 7

A foamed glass block may be produced by mixing together about 3 weightpercent minus 200 mesh calcium carbonate, about 3 weight percent P₂O₃,about 0.1 weight percent ZnO with the balance minus 60 mesh recycledcontainer glass. The mixture is loaded into a mold and heated to afoaming temperature of 1500 degrees Fahrenheit for 40 minutes. Theresulting article has a density of about 85 percent and a pore sizedistribution ranging from about 2 to 4 mm.

EXAMPLE 8

Glass pebbles are prepared by mixing together about 1 percent calciumcarbonate foaming agent sized about 10-20 micron median particle size,about 1 percent ZnO, about 0.2 percent calcium borate, with theremainder powdered soda-lime glass. The mixture is pressed into 2 mmdiameter pellets and fired without a mold to about 1500 degreesFahrenheit for foaming with a residence time of about 20 minutes,followed by a rapid air quench. The resulting articles have a porosityof between about 80 and 95 percent with a pore size ranging between 0.1and 2.5 mm. The resulting articles can be crushed to 3× pore size asneeded.

EXAMPLE 9

This Example provides some additional detail concerning the expedientmounding of the foamable mixture. A block of foamed glass materialsuitable for use as a plant growth support substrate is produced bythoroughly mixing together (such as for 20 minutes in a mechanicalmixer) about 2.5 weight percent calcium carbonate powder (100% of whichpasses through a 200 mesh screen), about 20 weight percent common sand(100% of which passes through a 40 mesh screen but which does not passthrough an 80 mesh screen), about 0.1 weight percent ZnO (100% of whichpasses through a 200 mesh screen), about 3 weight percent K₂O (100% ofwhich passes through a 200 mesh screen) with the balance being groundrecycled container glass (100% of which passes through a 325 meshscreen).

A ¼ inch stainless steel plate having a dimension of 20 inches.times.26inches is coated with a thin slurry of talc and alumina as agents toprevent sticking. A stainless steel mold is coated with the same slurry.The mold has the shape of a frustum and was open at the base. The basedimensions are 20 inches by 26 inches, and the peak dimensions are 19inches by 26 inches; the mold is 6 inches deep. The four portions of 3kg are divided from the batch, and each portion is placed on the 20 inchby 26 inch plate in a row such that it has base dimensions of 4.5 inchesby 16 inches. The four rows are typically evenly spaced 2 inches apart.The rows, which typically are oriented parallel to the long dimension ofthe plate, are spaced 1 inch away from the edge of the plate. The endsof the rows are placed 2 inches away from the short edges of the plate.Each row typically has a trapezoidal cross-section the base of which,such as 4.5 inches and the top of which is 3.5 inches, with a height of3 inches. Each portion may be compacted into the above shape, and thebulk density of the powder after being compacted is about 72 pounds percubic foot. A frustum shaped lid is lowered onto the plate supportingthe mounds of foamable mixture, whereupon the entire assembly is placedinto a furnace.

The furnace is rapidly heated to about 1250 degrees Fahrenheit and isheld for a one-hour soak to allow the foamable mixture to sinter andabsorb heat evenly. The temperature is then rapidly increased to 1500degrees Fahrenheit and held there for a one-hour soak. The mounds ofpowder then foam, fuse, and fill the mold. The temperature may then berapidly lowered to about 1050 degrees Fahrenheit and held there for atleast about 15 minutes to halt the foaming process and to solidify theoutside skin of the mass of foamed glass. The frustum shaped portion ofthe mold may then be removed from the mass of solidified foamed glass.The block of foamed glass article may then be placed in an annealinglehr to slowly cool the foamed glass article to ambient temperature, oralternately, the foamed glass article may be rapidly quenched to roomtemperature. The finished and cooled annealed block of foamed glass maythen be planed and trimmed to remove the glassy skin and traces ofrelease agent, and the finished cut block of foamed glass may be cut ormachined into any desired shape. The foamed glass article will have aporosity of about 90 percent and a pore size distribution ranging fromabout 2.0 to 5.0 mm.

FIGS. 3 and 5 illustrate other embodiments of the novel technology,hydroponic systems 40, 55 for growing plants. In FIG. 3, a hydroponicsystem 40 is disclosed wherein a substrate block 10 is partiallyimmersed in a fluid medium 42, such as water or an aqueous nutrientsolution. Roots 35 extend downwardly into the top of the substrate block10 through the interconnected open pores 15. Nutrient solution 42 iscarried upwardly into the block 10 via capillary action through the openpores.

FIG. 5 illustrates another embodiment of the present novel technology, asystem 55 including foamed glass pebbles or pellets 50 prepared asdetailed above and used in a soil-pellet mixture 57 into which plantroots 35 may extend. The pellets 50 are typically made of porous foamedglass material, but may alternately be made of porous glass material,such as formed by agglomerating and fusing together glass, metal orpolymer bodies, such as spheres 99 (see FIG. 9). The mixture 57 may, inaddition to the pellets 50, include soil, clay, peat moss, nitrates,fertilizer, manure or the like and mixtures thereof. Likewise, thepellets 50 may be used in place of perlite in soil admixtures. Thepellets 50 contribute by picking up, holding, and slowly releasingwater, as well as by providing a network of ‘anchors’ for the roots 35to extend into and through.

FIG. 6 illustrates still another embodiment of the present noveltechnology, a hydroponic system 70 including a bed 71 of foamed glassagglomerate media 50 into which roots 35 are growing. The media 50 areprepared and characterized as discussed above. Typically, the bed 71 isprepared in the form of bags of media 50 containing a substantiallyconstant, predetermined volume (such as, for example, 15 liters) ofmedia 50. More typically, the media 50 are loosely packed to define abed. The bags may be perforated and root systems 35 may extend throughthe bags and into the media 50. Likewise, water and nutrients may beapplied to the media 50 through the bags. Alternately, the media may beplaced into preformed containers, vessels, depressions or the like androots growing thereinto may be fed and irrigated by any convenienttechnique.

FIGS. 7 and 8 illustrate yet another embodiment of the present noveltechnology, a hydroponic system 80 similar to that discussed aboveregarding FIG. 6, but with a top unitary porous slab member or portion85 overlaying a layer 87 of loose crushed, pelletized or otherwiseparticulate media 50. Typically, the unitary slab portion 85 ispositioned atop the pelletized media layer 87, but the slab portion 85may alternately be positioned below the pelletized media layer 87. Moretypically, the slab member 85 and media 50 are formed from porous foamedglass as discussed above. Alternately, the slab portion 85 may be formedfrom rockwool, coconut coir, or other convenient fibrous or cellularmaterial, glass particles, glass or polymer or metal spheres (solid orhollow), or the like and combinations thereof (see FIG. 10). In someembodiments, the slab portion 85 and/or media 50 are formed fromagglomerations of (typically hollow) glass spheres, which may be packedtogether to define a porous material; more typically, the glass spheresare cemented or fused together to form a porous agglomerate body 85, 50.Likewise, the bottom layer 87 of particulate media 50 may alternatelyconsist of E-Stone, expanded clay, perlite, coco husk, agglomeratedglass particles/spheres, or other media and, more typically, allows forwater uptake at a lesser value than the top slab portion 85. Typically,the slab layer 85 is about as thick as the media layer 87, although thethickness of the slab portion 85 to the media layer 87 may be variedaccording to the growth needs of specific plants and/or in response tospecific growing conditions and/or climactic differences. The top layer85 typically allows for uniform or near uniform absorption of irrigationor nutrient fluid and, more typically, accepts at least twice it's massin water/nutrient fluid through capillary infiltration. More typically,the top layer accepts at least thrice its mass in water/nutrient fluid,and still more typically, the top layer accepts at least four times itsmass in water/nutrient fluid.

While the novel technology has been illustrated and described in detailin the drawings and foregoing description, the same is to be consideredas illustrative and not restrictive in character. It is understood thatthe embodiments have been shown and described in the foregoingspecification in satisfaction of the best mode and enablementrequirements. It is understood that one of ordinary skill in the artcould readily make a nigh-infinite number of insubstantial changes andmodifications to the above-described embodiments and that it would beimpractical to attempt to describe all such embodiment variations in thepresent specification. Accordingly, it is understood that all changesand modifications that come within the spirit of the novel technologyare desired to be protected.

What is claimed is:
 1. A method of growing plants, comprising the stepsof: a) providing a plurality of chemically stable porous glass pelletsdefining a substrate, each respective pellet characterized by aplurality of interconnected pores distributed throughout the pellet; b)at least partially filling the plurality of interconnected pores with anutrient fluid; and c) at least partially infiltrating the plurality ofinterconnected pores with roots; wherein the substrate is characterizedby a porosity of at least about 80 percent.
 2. The method of claim 1wherein the substrate is sufficiently chemically stable such that waterfilling the plurality of interconnected pores experiences a pH shift ofless than 0.5.
 3. The method of claim 1 wherein the substrate is filledwith between about 3 and about 4 times its own weight in water in theplurality of interconnected pores.
 4. The method of claim 1 wherein thepore size is substantially between about 0.5 and about 5 millimeters. 5.The method of claim 1 wherein the substrate includes about 2 weightpercent plant growth nutrients incorporated therein.
 6. The method ofclaim 1 wherein the substrate is at least partially composed of glassspheres.
 7. The method of claim 1 wherein the glass spheres areagglomerated and fused together to define a substantially poroussubstantially vitreous body.
 8. The method of claim 1 wherein thesubstrate is at least partially composed of fibrous organic material. 9.The method of claim 8 wherein the substrate is at least partiallycomposed of coconut cuir.
 10. The method of claim 1 and furthercomprising: d) providing a porous substrate member substantiallycovering the plurality of chemically stable porous foamed glass pellets.11. The method of claim 10 wherein the substrate member is a foamedglass slab characterized by about 80 percent open porosity andcharacterized by a typical pore size generally between about 0.5 andabout 5 millimeters.
 12. The method of claim 11 wherein the plurality ofchemically stable porous foamed glass pellets defines a bottom layer,wherein the foamed glass slab defines a top layer, wherein roots growthrough the porous top layer and into the interconnected pores of thebottom layer.
 13. The method of claim 10 wherein the porous substratemember is formed from a material selected from the group comprisingfoamed glass, glass spheres, coconut cuir, rockwool, polymer spheres,metal spheres, and combinations thereof.
 14. A method of nourishing andanchoring roots, comprising the steps of: a) positioning a plurality ofchemically stable porous pellets, each respective pellet characterizedby a plurality of interconnected pores distributed throughout the pelletto define a bottom layer; b) covering the bottom layer of chemicallystable porous pellets with a unitary slab characterized byinterconnected open porosity and defining a top layer; c) at leastpartially filling the plurality of interconnected pores with a nutrientfluid; and d) at least partially infiltrating the plurality ofinterconnected pores with roots.
 15. The method of claim 14 wherein theunitary slab is foamed glass.
 16. The method of claim 14 wherein theplurality of interconnected pores are generally sized between about 0.5and about 5 millimeters and wherein the unitary slab is characterized byan open porosity of between abut 0.5 and about 5 millimeters.
 17. Themethod of claim 14 wherein the unitary slab and substantially eachrespective pellet may hold at least about 3 times its respective weightin water.
 18. The method of claim 14 wherein the chemically stableporous pellets are formed from a material selected from the groupcomprising foamed glass, glass spheres, coconut cuir, rockwool, polymerspheres, metal spheres, and combinations thereof.
 19. A method ofnourishing and anchoring roots, comprising the steps of: a) positioninga plurality of chemically stable porous glass pellets, to define a firstlayer; b) positioning a unitary porous foamed glass slab adjacent the afirst layer to define a second layer; c) at least partially infiltratingthe first and second layers with a nutrient fluid; and d) at leastpartially infiltrating the plurality of interconnected pores with roots;wherein the respective first and second layers hold at least about 3times their respective weights in water; and wherein the respectivefirst and second layers are characterized by open, interconnected poressized to allow passage of plant roots therethrough.
 20. The method ofclaim 19 wherein the first and second layers are sufficiently chemicallystable such that water filling infiltrating a respective layerexperiences a pH shift of less than 0.5.
 21. The method of claim 19wherein at least one layer includes plant growth nutrients adsorbed ontopore surfaces.
 22. The method of claim 19 wherein at least one layerincludes about herbicide adsorbed onto pore surfaces.
 23. The method ofclaim 19 wherein at least one layer includes pesticide adsorbed ontopore surfaces.